INTRODUCTION Installation requires a professional mechanic. Prior to beginning, inspect the vehicle s steering, driveline, and brake systems, paying close attention to the suspension link arms and bushings, stabilizer bars and bushings, tie rod ends, steering rack, ball joints and wheel bearings. Also check the steering and all suspension-to-frame attaching points for stress cracks. The overall vehicle must be in excellent working condition; repair or replace all worn parts. Read instructions several times before starting. Be sure you have all needed parts and know where they install. Read each step completely as you go. NOTES: Prior to beginning the installation, check all parts and hardware in the box with the parts list below. If you find a packaging error, contact Mopar directly. Do not contact the dealer where the system was originally purchased. You will need the control number from each box when calling; this number is located at the bottom of the part number label and to the right of the bar code. Front-end realignment is necessary. In photos, an arrow indicates which direction is towards front of vehicle. A foot-pound torque reading is given in parenthesis ( ) after each appropriate fastener. Do not fabricate any components to gain additional suspension height. Prior to drilling or cutting, check behind the surface being worked on for any wires, lines, or hoses that could be damaged. After drilling, file smooth any burrs and sharp edges. Prior to operating a torch or saw, protect any heat-sensitive components located in the immediate area by covering them with a water-saturated cloth. Most undercoatings are flammable but can be extinguished using a water-filled spray bottle. Have a spray bottle and an ABC rated fire extinguisher on hand. Paint or undercoat all metal surfaces after cutting / drilling. Prior to attaching components, be sure all mating surfaces are free of grit, grease, excessive undercoating, etc. A factory service manual should be on hand for reference. Use the check-off found at each step to help you keep your place. Two denotes that one check-off box is for the driver side and one is for the passenger side. NOTE: Vehicle RPM and speedometer readings are based on the stock vehicle s tire and wheel combinations. Installing larger wheels and tires with your Mopar Performance lift kit could result in incorrect RPM, speedometer and odometer readings. K6857310 03/15/13 Page 1 of 21
Wheel and Tire Recommendations Tire Diameter: Up to 36 Tire Width: 12.5 Wheel Diameter: 18 and up (17 wheel does not work) Wheel Width: Stock to 9. Do not use less than an 8 wide wheel with a 12.5 wide tire. Wheel Back Spacing: 18 diameter wheels minimum of 5. Stock to 5.5 for 20 diameter wheels. As Back Spacing dimension decreases, track width and stability increases. PARTS LIST The part number is stamped into each part or printed on an adhesive label. Identify each part and place the appropriate mounting hardware with it. PART NO. DESCRIPTION NEW ATTACHING BAG # (Qty.- if more than one) HARDWARE (Qty.) 66-01-4594. knuckle, driver. (1) Threadlocker 77-4594-2 66-02-4594. knuckle, passenger. (1) Threadlocker 77-4594-2 55-03-4594. front diff. bracket, driver / front.. (2) 12mm x 60mm bolt 77-4603 (6) 12mm flat washer (2) 12mm Stover nut (2) 12mm x 40mm bolt (2) 12mm lock washer 55-03-4603. front diff. bracket, driver / rear (3) 12mm x 40mm bolt 77-4603 (3) 12mm lock washer (6) 12mm flat washer 55-04-4594. front diff. bracket, pass. side (2) 1/2 x 2-1/4 bolt 77-4603 (2) 1/2 Stover nut (2) 12mm Stover nut (2) 12mm flat washer (4) 1/2 SAE flat washer 55-05-4603.differential actuator bracket K6857310 03/15/13 Page 2 of 21
PART NO. DESCRIPTION NEW ATTACHING BAG # (Qty.- if more than one) HARDWARE (Qty.) 55-46-4594. front crossmember, lower.. (2) 18mm x 150 bolt 77-4594-2 control arms front legs (4) 3/4 SAE flat washer (2) 2 x 1-1/2 x 3/16 thick lockout tabs (2) 18mm Nyloc nut 55-49-4594. front crossmember, lower.. (2) 18mm x 150 bolt 77-4594-2 control arms rear legs (4) 3/4 SAE flat washer (2) 2 x 1-1/2 x 3/16 thick lockout tabs (2) 18mm Nyloc nut 55-08-4594. front belly pan.. (6) 3/8 x 1 countersunk blt.77-4594-4 (6) 3/8 Flange nut 55-10-4594.(2) front strut spacer..... (6) 7/16 Flange nut 77-4594-3 OR (55-10-4595)...(2) Outdoorsman frt strut spacer..(6) 7/16 SAE flat washer OR BE5-F812-H0 (2) Bilstein Struts 55-11-4594. front brake line bracket, pass.(1) 3/8 Flange nut 77-4594-3 (1) 3/8 x 1 bolt (1) 1/4 x 3/4 bolt (1) 1/4 Nyloc nut 55-12-4594. front brake line bracket, driver...(1) 3/8 Flange nut 77-4594-3 (1) 3/8 x 1 bolt (1) 1/4 x 3/4 bolt (1) 1/4 Nyloc nut 55-23-4640. (2) front stabilizer bar link ext (6) 7/16 SAE flat washer 77-4594-3 K6857310 03/15/13 Page 3 of 21
PART NO. DESCRIPTION NEW ATTACHING BAG # (Qty.- if more than one) HARDWARE (Qty.) 66-04-4603. front driveshaft spacer....(4) 12mm x 50mm bolt 77-4594-3 55-15-4594... rear link arm bracket, driver... (1) 1/2 x 1-1/4 bolt 77-4594-5 (1) 5/8 x 4-1/2 bolt (1) 5/8 x 4 bolt (4) 5/8 SAE flat washer (2) 5/8 Stover nut (1) 1-1/4 O.D. x 2-3/8 long sleeve (1) 55-12-4540 Tab nut 55-16-4594... rear link arm bracket, pass.... (1) 1/2 x 1-1/4 bolt 77-4594-5 (1) 5/8 x 4-1/2 bolt (1) 5/8 x 4 bolt (4) 5/8 SAE flat washer (2) 5/8 Stover nut (1) 1-1/4 O.D. x 2-3/8 long sleeve (1) 55-12-4540 Tab nut 55-18-4594... rear track bar bracket... (2) 7/16 x 1-1/4 bolt 77-4594-5 (1) 1-1/8 O.D. x 1-7/16 long sleeve (4) 7/16 SAE flat washer (1) 9/16 x 3-1/2 bolt (2) 9/16 SAE washer (1) 9/16 Nyloc nut (2) 7/16 Nyloc nut 55-22-4594. rear track bar bracket support plate 55-19-4594. (2) rear stabilizer bar/brake line (2) 7/16 x 1 bolt 77-4594-5 bracket (4) 7/16 SAE flat washer (2) 7/16 Nyloc nut (2) 5/16 x 1 bolt (4) 5/16 SAE flat washer (2) 5/16 Nyloc nut K6857310 03/15/13 Page 4 of 21
PART NO. DESCRIPTION NEW ATTACHING BAG # (Qty.- if more than one) HARDWARE (Qty.) 55-37-4594. rear bump stop extension, driver.. (2) 3/8 x1 bolt 77-4594-6 (2) 3/8 SAE flat washer (2) 3/8 Nyloc nut 55-36-4594. rear bump stop extension, pass... (2) 3/8 x1 bolt 77-4594-6 (2) 3/8 SAE flat washer (2) 3/8 Nyloc nut Shock absorber part number depends on type ordered. (2) rear shock absorber decal (2) hardware pack 02-141..(2) rear coil spring 716249 Mopar decal sheet.in Installation Instructions packet FRONT PROCEDURE NOTE: Save all factory components and hardware for reuse, unless noted. 1) PREPARE VEHICLE Place vehicle in neutral. Raise front of vehicle with a jack and secure a jack stand beneath each frame rail, behind the lower link arms. Ease the frame down onto the stands, place transmission in low gear or park, and chock rear tires. Remove front tires. 2) FRONT DIFFERENTIAL SKID PLATE AND DRIVESHAFT If equipped, remove the factory front differential skid plate and discard. Mark the driveshaft and yoke to reassemble in the same orientation. Disconnect the front driveshaft from the differential then secure driveshaft up and out of the way. 3) STABILIZER BAR LINKS Disconnect the upper end of the stabilizer bar links from the stabilizer bar; leave the lower ends attached to the lower control arm. Perform steps 4 through 7 one side at a time. 4) WHEEL SPEED SENSORS Detach the Wheel Speed Sensor (WSS) wire at the following points, and in this order: A) At rubber brake hose B) At rear leg of upper control arm K6857310 03/15/13 Page 5 of 21
C) At engine compartment side of the inner fenderwell. This attachment point is just above attachment point B, and is accessed by pulling the plastic inner fender outboard slightly. Point C is also a WSS wire plug / connector; disconnect the WSS wire here. 5) KNUCKLES Remove the brake caliper from the rotor and secure it away from the work area. NOTE: Do not let calipers hang from brake lines. Remove the front rotor from the hub. Remove the retaining nut from the center of the bearing hub. Loosen, but do not remove, the upper control arm bolts. Using the appropriate puller tool, disconnect the upper and lower ball joints and outer tie rod end from the knuckle. Remove knuckle. The wheel speed sensor wire remains on the factory knuckle for now. 6) STRUTS Loosen, but do not remove, the lower control arm bolts. Remove the lower strut bolt. Remove the three upper strut assembly bolts. Remove strut. 7) LOWER CONTROL ARMS Remove the lower control arm s two alignment cam bolt assemblies then remove the lower control arm. Repeat steps 4 through 7 on opposite side. 8) REAR CROSSMEMBER Remove the factory lower control arms rear crossmember. 9) DIFFERENTIAL Disconnect all electrical lines from differential. Support the differential and remove all differential-to-frame mounting hardware. Remove differential assembly. K6857310 03/15/13 Page 6 of 21
10) TRIMMING FRONT AND REAR / LOWER CONTROL ARM MOUNT [See Photo 1 and 1A] The front driver and passenger side lower control arm mount must be trimmed. Measure down 1 from the bottom edge of the slot and mark a line parallel to the slot. Cut the frame through the front side only along the marked line using a cut-off wheel or Sawz-all. After cutting, clean and paint all exposed areas. The passenger side factory rear / lower control arm mount must be trimmed as shown. Measure down from the bottom edge of the slot and mark a line parallel to the slot. Cut the frame through the front side only along the marked line using a cut-off wheel or Sawz-all. After cutting, clean and paint all exposed areas. The driver side factory rear / lower control arm mount must be trimmed as shown. Measure to the inside 1-3/4 from inside edge of slot and mark a line perpendicular to the bottom edge of the slot. Cut the frame through all sides along the marked lines (front, top and back sides) using a cut-off wheel or Sawz-All. After the first cut, measure down from the bottom edge of the slot 15/16 and mark and line parallel with the bottom edge of the slot on the front side of the factory mount. Cut the frame through the front side only along the marked line using a cut-off wheel or Sawz-All. After cutting, clean and paint all exposed areas. K6857310 03/15/13 Page 7 of 21
K6857310 03/15/13 Page 8 of 21
11) DIFFERENTIAL BRACKETS [See Photo 2] Loosely attach the driver side / front differential bracket (55-03-4594) to the frame using the supplied 12mm x 40mm bolts, lock washers, and flat washers. Do not tighten. [See Photo 3] Loosely attach the driver side / rear differential bracket (55-03-4603) to the frame using the factory bolts and supplied flat washers. Do not tighten. [See Photo 4] Loosely attach the passenger side differential bracket (55-04- 4594) and the differential actuator bracket (55-05-4603) to the frame using the supplied 12mm x 70mm bolts and flat washers and Stover nuts. Do not tighten. Note that the actuator bracket should be placed between the 55-04-4594 and the bolt head with the third hole positioned on the passenger side. 12) CV AXLES On each side, disconnect the inner CV axle assembly from the differential. Use two pry bars, positioned between the inner CV and the differential housing, to free the axles. 13) INSTALL DIFFERENTIAL AND MOPAR REAR CROSSMEMBER ( 55-49-4594) Position the differential in the frame - Loosely attach the differential to the Mopar driver side / front bracket using the supplied 12mm x 60mm bolts, flat washers (on both nut and bolt head sides) and Stover nuts. Do not tighten. The differential is attached to the remaining Mopar brackets in later steps. Mopar rear crossmember, passenger side - Raise the passenger side of the differential housing which will allow you to mate the passenger side of the Mopar crossmember - to - frame. Insert the supplied 18mm x 150mm bolt and flat washer from the front, through the factory mount K6857310 03/15/13 Page 9 of 21
crossmember. Position the 2 x 1-1/2 x 3/16 thick lockout tab onto the bolt; the tab seats in what was the factory rear cam washer s location. Install the supplied flat washer then the supplied 18mm Nyloc nut. Do not tighten. Note the crossmember goes inside of the factory mount. Mopar rear crossmember, driver side - Position the driver side of the Mopar crossmember into the frame. Insert the supplied 18mm x 150mm bolt and flat washer from the front, through the factory mount and crossmember. Position the 2 x 1-1/2 x 3/16 thick lockout tab onto the bolt; the tab seats in what was the factory rear cam washer s location. Install the supplied flat washer then the supplied 18mm Nyloc nut. Do not tighten. Note the crossmember goes inside of the factory mount. Differential - to - Mopar passenger side bracket - Loosely attach using the supplied 1/2 x 2-3/4 bolts, flat washers (on both nut and bolt head sides) and Stover nuts. Do not tighten. Differential - to - Mopar driver side / rear bracket - Attach using the three factory differential bolts and the supplied nuts that were earlier removed from the factory rear crossmember. Tighten all differential hardware to (70) in the order listed: the four bolts securing the driver side / front bracket ; the four bolts securing the passenger side bracket; the six bolts securing the driver side / rear bracket. Leave the two crossmember - to - frame bolts loose at this time. Insert the 5/16 vacuum line adapter (23-3205) and new vacuum line (18-9690). Reconnect the electrical lines; retaining clips may need to be removed to create enough slack to reconnect. 14) MOPAR FRONT CROSSMEMBER (55-46-4594) Position the Mopar crossmember into the frame; make sure the tab with the skid plate holes are towards the rear of the vehicle. Insert the supplied 18mm x 150mm bolt and flat washer from the front, through the factory mount and crossmember. Position the 2 x 1-1/2 x 3/16 thick lockout tab onto the bolt; the tab seats in what was the factory rear cam washer s location. Install the supplied flat washer then the supplied 18mm Nyloc nut. Do not tighten. Note the crossmember goes inside of the factory mount 15) FRONT DRIVESHAFT [See Photo 3] Install driveshaft spacer (66-13-4594) between the differential mounting flange and the driveshaft using the supplied 12mm x 50mm bolts. Line up marks made in step 2. Apply threadlocker to the bolts before installation. Tighten (85). Perform steps 16 through 20 one side at a time. K6857310 03/15/13 Page 10 of 21
16) LOWER CONTROL ARMS Loosely install the factory lower control arm reusing the factory cam bolts assemblies. Insert bolts from the front with the cam lobes in the upright / centered position. Do not tighten. Note: It is possible to incorrectly install the driver side lower control arm on the passenger side of the vehicle, and vice-versa. When the control arm is located properly, the stabilizer bar links will be positioned towards front of vehicle, and the lower ball joint stud points down. IF REPLACEMENT BILSTEIN STRUTS WERE NOT PURCHASED, SKIP TO STEP 17A. 17) REPLACEMENT STRUTS Locate the factory strut assembly. Use a paint marker to scribe three vertically aligned indexing marks on the outboard side of the assembly. Mark: 1) the outboard facing side of the upper strut mounting plate, 2) the top (exposed) coil spring wrap, 3) the center of the lower strut eye mount. WARNING! The coil is under extreme pressure and severe bodily injury may occur if the coil spring is disassembled without using a suitable coil spring compressor. Compress the coil spring until the strut body has approximately 3/8 of free movement. Remove the upper strut mounting plate retaining nut. NOTE: Do not use an impact gun to remove the retaining nut; this may damage the strut shaft. Remove the washer then the strut s upper bushing half. Remove the strut s upper mounting plate then the factory coil spring isolator. Carefully remove the strut cylinder from the coil spring.. [See Photo 6A] Once the strut has been removed, slide the rubber snubber from the shaft, stand the strut up on the shaft end and carefully remove the strut end cap, then remove the lower coil seat [See Photo 6B] Position the snap ring on the new strut in the end groove closest to the shaft, then slide the K6857310 03/15/13 Page 11 of 21
lower seat collar onto the snap ring. The collar may need to be carefully tapped in place with a hammer. Slide the lower coil seat onto the collar and tap into place. Positi on the machi ned space r on the shock body follow ed by the lower coil seat, insert the shock inside the coil and rotate the coil until the coil is seated properly in the lower coil seat. Install the nyloc nut and tighten. Slowly decompress the coil spring on the strut assembly. Make sure that the spring is seated correctly into the strut assembly. Position the strut spacer (55-10-4594) onto the top of the factory strut using the factory hardware. Tighten (45). K6857310 03/15/13 Page 12 of 21
Install the strut assembly by first loosely attaching the strut s upper studs to the factory frame mount using the supplied 7/16 SAE flat washers and Stover nuts; do not tighten. Now raise the lower control arm, and insert the factory lower strut hardware. Tighten the upper hardware (45). Do not tighten the lower strut hardware at this time. Repeat step on opposite side IF REPLACEMENT BILSTEIN STRUTS WERE INSTALLED, SKIP TO STEP 18 17A) STRUT SPACERS... Position the strut spacer (55-10-4594 or 55-10-4595 for TRX models) onto the top of the factory strut using the factory hardware. Tighten (45). Install the strut assembly by first loosely attaching the strut s upper studs to the factory frame mount using the supplied 7/16 SAE flat washers and Flange nuts; do not tighten. Now raise the lower control arm, and insert the factory lower strut hardware. Tighten the upper hardware (45). Do not tighten the lower strut hardware at this time. 18) CV AXLES Insert the inner CV axle shaft into the differential then push firmly to engage CV axle shaft retaining ring. 19) BRAKE LINE / HOSE RELOCATION [See Photo 6] Locate where the upper end of the rubber brake hose passes through the frame and connects to a metal brake line. Use the appropriate tool (ex: cut-off wheel) to cut a notch in the frame to allow removal of the brake hose / line connector. Take care NOT to damage the brake line / hose. Remove the brake line bracket bolt then free the line / hose connector from frame. There are a couple of bends in the metal line, just above the line / hose connector. Carefully re-form (straighten-out) the bends, as needed, to allow the factory brake line bracket to mate with the bracket. DO NOT kink the line. Attach the factory brake line bracket to the brake line bracket (55-12-4594 driver and 55-11-4594 passenger) using the supplied 1/4 x 3/4 bolt and Nyloc nut. Attach brake line bracket - to - frame using the supplied 3/8 x 1 bolt and Flange nut in the top hole and the factory hardware in the bottom hole. Tighten the 3/8 hardware (30). Tighten the factory and 1/4 hardware (76 In. Lbs.) 20) KNUCKLE INSTALLATION K6857310 03/15/13 Page 13 of 21
Remove the bolt that secures the Wheel Speed Sensor (WSS) wire mounting bracket to the factory knuckle. Attach this bracket to the knuckle in the same orientation as factory. Remove the hub assembly and dust shield from the factory knuckle. Do not disconnect the WSS wire from the hub assembly. Position the factory hub assembly and dust shield onto the new knuckle (66-01-4594 driver and 66-02-4594 passenger). The hub must be positioned with the WSS wire routed forward and inside the relief machined into the knuckle face. Apply threadlocker to the factory hardware then fasten hub assembly and dust shield to the knuckle. Tighten (95). [See Photo 7] Route the WSS wire to the mounting bracket on the knuckle, as shown. The rubber grommet on the WSS wire must be shifted. Lubricate the WSS wire and rubber grommet with a detergent-based cleaner (ex: Windex, Formula 409, silicone ), which allows the WSS wire to slide easily through the rubber grommet. When satisfied with routing, insert the WSS wire / rubber grommet into the mounting bracket. Install knuckle onto vehicle. Attach the lower ball joint first then slide the CV axle shaft through the hub bearing. Next connect the upper ball joint and tie rod end. Reuse the factory hardware, and apply threadlocker to all. Tighten the lower ball joint nut (85), upper ball joint nut (50), CV axle shaft nut (100) and the tie rod nut (85). Install the brake rotor and caliper using the factory hardware. Apply threadlocker to caliper bolts. Tighten (130). Route / reattach the Wheel Speed Sensor (WSS) wire at the following points, and in this order. Again, it will be necessary to lubricate the grommets / WSS wire to allow movement: A) At rubber brake hose B) At rear leg of upper control arm C) Reconnect the WSS wire plug / connector. Do not reattach the connector to the inner fenderwell. K6857310 03/15/13 Page 14 of 21
Repeat steps 16 through 20 on opposite side. 21) STABILIZER BAR LINK EXTENSIONS Apply anti-seize to the factory stabilizer bar link threads. Install three 7/16 SAE washers per side then install the stabilizer bar link extensions (55-23-4640). Reuse factory bushings and hardware. Attach stabilizer bar links to stabilizer bar body. Tighten until bushings swell slightly. 22) BELLY PAN [See Photo 8] Attach the belly pan (55-08-4594) to the lower control arm crossmembers using the six supplied 3/8 x 1 countersunk bolts and Flange nuts. Tighten (30). Tighten all four crossmember - to - frame bolts (75). 23) TIRES / WHEELS [See Photo 9] Tighten the lug nuts in the sequence shown (130). WARNING: When the tires / wheels are installed, always check for and remove any corrosion, dirt, or foreign material on the wheel-mounting surface, or anything that contacts the wheelmounting surface (hub, rotor, etc.). Installing wheels without the proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion. WARNING: Retighten lug nuts at 500 miles after any wheel change, or anytime the lug nuts are loosened. Failure to do so could cause wheels to come off while vehicle is in motion. Lower vehicle to the floor. The suspension is now supporting vehicle weight. 24) TORQUE CONTROL ARMS AND STRUTS Tighten the lower control arm bolts (110). Tighten the lower strut bolts (155). Tighten the upper control arm bolts (130). 25) CLEARANCE CHECK Raise the vehicle back onto jack stands and secure as per step 1. With the suspension hanging at full extension travel, cycle steering lock-to-lock and check all components for proper operation and clearances. Pay special attention to the clearance between the tires / wheels and knuckles, brake hoses, wiring, etc. Lower the vehicle to the floor. REAR PROCEDURE K6857310 03/15/13 Page 15 of 21
26) PREPARE VEHICLE Before raising the rear of the vehicle: Disconnect the upper end of the track bar. Loosen, but do not remove, the track bar at the driver side axle mount. Disconnect the upper ends of the stabilizer bar links where they attach to the frame. Disconnect the brake line mount and wheel speed sensor. Both are located on the frame, behind the coil spring s upper mount. Remove the bolt securing the wire hanger bracket that captures the parking brake cables. This hanger is bolted to the driver side, lower suspension link arm. Retain hardware. 27) RAISE REAR OF VEHICLE Position a jack beneath the center of the rear axle then raise rear of vehicle. Secure jack stands beneath the frame rails just forward of the lower link arms. Chock front tires to prevent any possibility of movement. Remove rear tires. 28) SHOCKS AND COIL SPRINGS Remove shock absorbers. Lower the axle just enough to allow removal of coil springs. 29) SUSPENSION LINK ARMS [See Photo 10] Perform this step one side at a time. Loosen, do not remove, all four suspension link arms where they attach to the axle. Disconnect all four link arms from the frame. Position the link arm relocation bracket (55-15-4594 driver and 55-16-4594 passenger) as shown then attach as follows using supplied hardware. No hardware is tightened at this time. A) At lower factory link arm mount use 5/8 x 4 bolt, SAE flat washers (on both nut and bolt head sides) and Stover nut. Bolt installs from the outside. B) At upper factory link arm mount, position frame sleeve (1-1/4 O.D. x 2-3/8 long) then 5/8 x 4-1/2 bolt, SAE flat washers (on both nut and bolt head sides) and Stover nut through the front lower mounting hole. Bolt installs from the outside. K6857310 03/15/13 Page 16 of 21
C) At hole in front bottom side of bracket (where bracket mates to bottom of frame rail), insert the 1/2 x 1-1/4 bolt (facing towards rear of vehicle) through the bracket and frame then into the tab nut (55-12-4540). Loosely re-attach the factory link arms to the relocation bracket using factory hardware. Bolts install from the outside. Do not tighten. Tighten the supplied 5/8 hardware (150) then the supplied 1/2 hardware (75). Do not tighten factory link arm hardware at this time. 30) TRACK BAR BRACKET [See Photo 11] Mate the track bar bracket (55-18-4594), support plate, (55-22-4594) and sleeve (1-1/8 O.D. x 1-7/16 long) to the factory track bar frame bracket, as shown. The support plate attaches to the rear face of both brackets (adding this bracket sandwiches the factory bracket between the 18 and 22 brackets). Insert the supplied 9/16 x 3-1/2 bolt, flat washers (on both nut and bolt head sides), and Nyloc nut. Tighten (105). Two 7/16 holes must be drilled through the factory track bar frame bracket. Using the upper hole in track bar bracket and the support plate as a template, mark and drill. Insert the two supplied 7/16 x 1-1/4 bolt, flat washers (on both nut and bolt head sides), and Nyloc nut. Tighten (50). K6857310 03/15/13 Page 17 of 21
31) WHEEL SPEED SENSOR WIRE [See Photo 12] Remove the Wheel Speed Sensor (WSS) wire s front and rear clips. The front clip is located on the front / outboard side of the shock absorber s lower mount, and the rear clip is on the outside edge of the coil spring s lower seat. Reposition the front clip into the factory rear clip s hole, at the base of the coil spring seat, and discard the rear clip. 32) BUMP STOPS [See Photo 13] Position the passenger side bump stop bracket (55-36-4594), as shown, on top of the factory bump stop pad, located on top of the axle tube, just inboard of the coil springs. The hooks on the back side of the bracket capture the underside of the factory bump stop pad. Center the bracket on the pad then using the holes in the bracket as a template, drill two holes through the factory pad for the 3/8 mounting hardware. Insert the supplied 3/8 x 1 bolts (installed from top), flat washers (on nut side), and Nyloc nuts. Tighten (30). The driver side bump stop bracket (55-37-4594) attaches through pre-existing holes in the factory pad. It uses the same hardware as the passenger side. 33) COIL SPRINGS AND SHOCKS Install coil springs and shock absorbers using the factory hardware and supplied shock bushings and sleeves. Do not tighten. Apply shock decals. 34) BRAKE LINE / STABILIZER BAR BRACKET [See Photo 14] Perform this step one side at a time. The WSS wire is clipped to the front face of the factory stabilizer bar link s frame bracket. Detach WSS clip from the bracket. Position the brake line / stabilizer bar relocation bracket (55-19-4594) over the factory bracket. Use the factory hardware in the top hole, and the supplied 7/16 x 1 bolt, flat washers (on both nut and bolt head sides) and Nyloc nut in the next hole down. Use the supplied 5/16 x 1 bolt, flat washers (on both nut and bolt head sides) and Nyloc nut to attach the factory brake line bracket-to-bracket. Tighten K6857310 03/15/13 Page 18 of 21
the 7/16 hardware (50). Tighten the 5/16 hardware (200 in. Lbs.). Tighten the factory hardware (top hole) (23). Loosely attach the upper end of the stabilizer bar link to the bracket using factory hardware. Do not tighten. [See Photo 15] The WSS wire clip, detached in the first step, plugs into a hole in the front face of the bracket. [See Photo 15] There are three more WSS wire clips per side. Lubricate all then feed the WSS wire up and along the brake hose / line so the end result is as shown. 35) TIRES / WHEELS [See Photo 16] Tighten the lug nuts in the sequence shown (130). WARNING: When the tires / wheels are installed, always check for and remove any corrosion, dirt, or foreign material on the wheel-mounting surface, or anything that contacts the wheel-mounting surface (hub, rotor, etc.). Installing wheels without the proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion. WARNING: Retighten lug nuts at 500 miles after any wheel change, or anytime the lug nuts are loosened. Failure to do so could cause wheels to come off while vehicle is in motion. Lower vehicle to the floor. The suspension is now supporting vehicle weight. 36) REAR HARDWARE TIGHTENING SEQUENCE Suspension link arms to the brackets (210). Suspension link arms to the axle (210). Shock absorbers (100). Reconnect upper end of track bar using the factory hardware (130). Tighten track bar s lower end (130). Stabilizer bar links to the brackets (80). K6857310 03/15/13 Page 19 of 21
37) PARKING BRAKE CABLES [See Photo 17] Reattach the parking brake cables wire hanger bracket to the driver side, lower suspension link arm, but only capture the passenger side cable; leave the driver side cable loose. Tighten the hanger bracket to the link arm bolt (35). 38) REAR WHEEL LINER [See Photo 18] On trucks equipped with the plastic rear wheel liners the liner may have to be trimmed to minimize contact to the tire. Trim the liner horizontally on the angled face above the area of contact. Leave the two fasteners intact and trim the liner at an angle on each end to meet the bottom of the liner. Paint any exposed surfaces black for best appearance. 39) FINAL CLEARANCE AND TORQUE CHECK With vehicle on floor, cycle steering lockto-lock and inspect the tires / wheels, and the steering, suspension, and brake systems for proper operation, tightness, and adequate clearance. 40) FOUR WHEEL DRIVE Activate four-wheel drive system and check for proper engagement. 41) HEADLIGHTS Readjust headlights to proper setting. 42) WARNING DECAL Install the WARNING TO DRIVER decal on the inside of the windshield, or on the dash, within driver s view. 43) ALIGNMENT Realign vehicle to factory specifications. A precise alignment, including the centering of the steering wheel, is required in order for the vehicle s Electronic Stability Program to function properly. A laser alignment is recommended. Important Maintenance Information It is the ultimate buyer s responsibility to have all bolts / nuts checked for tightness after the first 100 miles and then every 1000 miles. The steering, suspension and driveline systems, plus wheel alignment should be inspected by a qualified professional mechanic at least every 3000 miles. Mopar Performance Suspension Limited Lifetime Warranty by LKI Inc. K6857310 03/15/13 Page 20 of 21
Your warrantor is LKI Enterprises, Inc. (LKI). The entire product warranty process is handled by LKI, not by Chrysler LLC, any Jeep or Dodge vehicle dealership, or any Mopar distributor or retailer. This product is covered by the Limited Warranty explained below that gives you specific legal rights. This Limited Warranty is the only warranty LKI, or any other manufacturer, dealer or distributor makes in connection with your performance suspension accessories. Your performance suspension involves several unique WARNINGS, and installation of these parts may affect other portions of your Jeep or Dodge vehicle warranties read carefully. What is covered? Subject to the terms below, LKI will repair or replace its products found defective in materials or workmanship for so long as the original purchaser owns the vehicle on which the product was originally installed. What is not covered? The addition of performance parts does not by itself void a vehicle s warranty. However, added performance parts (parts not originally supplied on the vehicle from the factory) are not covered by the vehicle s warranty, and any failure that they may cause is also not covered by the vehicle s warranty. Additionally, your LKI Limited Warranty does not cover products, parts or vehicles LKI determines to have been damaged by or subjected to: Alteration, modification or failure to maintain. Normal wear and tear (bushings, tie-rod ends, etc.). Scratches or defects in product finishes (powder coating, plating, etc.), Damage to or resulting from vehicle s electronic stability system, related components or other vehicle systems. Racing or other vehicle competitions or contests. Accidents, impact by rocks, trees, obstacles or other aspects of the environment. Theft, vandalism or other intentional damage. Remedy Limited to Repair / Replacement. The exclusive remedy provided hereunder shall, upon LKI s inspection and at LKI s option, be either repair or replacement of product or parts covered under this Limited Warranty. Customers requesting warranty consideration should contact LKI by phone (1-800-551-4955) to obtain a Returned Goods Authorization number. All removal, installation and shipping costs are customer s responsibility. If a replacement part is needed before the Mopar part in question can be returned to LKI, you must first purchase the replacement part from LKI. Then, if the part in question is deemed warrantable, you will be credited / refunded by LKI. Other Limitations - Exclusion of Damages - Your Rights Under State Law Neither LKI, Chrysler LLC, nor your Jeep or Mopar dealer are responsible for any time loss, rental costs, or for any incidental, consequential or other damages you may have. This Limited Warranty gives you specific rights. You may also have other rights that vary from state to state. For example, while all implied warranties are disclaimed herein, any implied warranty required by law is limited to the terms of our Limited Lifetime Warranty as described above. Some states do not allow limitations of how long an implied warranty lasts and / or do not allow the exclusion or limitation of incidental or consequential damages, so the limitations and exclusions herein may not apply to you. MOPAR DIRECT CONNECTION TECH LINE LKI WARRANTY LINE 1-888-528-HEMI (4364) 1-800-551-4955 K6857310 03/15/13 Page 21 of 21